Embossing method

An embossing method to form an embossed web material, comprising the steps of:

• passing a deformable web material between a first embossing roll and a second embossing roll engaged with each other, to emboss the deformable web material to form an embossed web material, wherein
• the first embossing roll has a first embossing pattern engraved on at least a portion of the peripheral surface of the first roll, the first embossing pattern comprising protrusions and recessions;
• and
• the second embossing roll has a second embossing pattern engraved on at least a portion of the peripheral surface of the second embossing roll, the second embossing pattern comprising protrusions and recessions, and
• wherein the protrusions of the first embossing pattern of the first embossing roll become inter-engaged at a radial depth of engagement with the corresponding recessions of the second embossing pattern of the second embossing roll such that at least 99.7% of the inter-engaged protrusions and recessions are separated from each other by a sidewall clearance ranging from about 0.002″ (about 0.050 mm) to about 0.050″ (about 1.27 mm).

An embossing method to form an embossed web material, comprising the steps of:

• passing a deformable web material between a first embossing roll and a second embossing roll engaged with each other, to simultaneously emboss and transfer an active substance to the deformable web material to form an embossed web material, wherein
• the first embossing roll has a first embossing pattern engraved on at least a portion of the peripheral surface of the first roll, the first embossing pattern comprising protrusions and recessions;
• and
• the second embossing roll has a second embossing pattern engraved on at least a portion of the peripheral surface of the second embossing roll, the second embossing pattern comprising protrusions and recessions, and
• wherein the protrusions of the first embossing pattern of the first embossing roll become inter-engaged at a radial depth of engagement with the corresponding recessions of the second embossing pattern of the second embossing roll such that at least 99.7% of the inter-engaged protrusions and recessions are separated from each other by a sidewall clearance ranging from about 0.002″ (about 0.050 mm) to about 0.050″ (about 1.27 mm).

An embossing method to form an embossed web material having an active substance protected from inadvertent contact with an external surface until the embossed web is deformed, the method comprising the steps of:

• (a) passing a deformable web material between a first embossing roll and the second embossing roll engaged with the first embossing roll, to emboss the deformable web material to form the embossed web material having an active substance, wherein
• the first embossing roll has a first embossing pattern engraved on at least a portion of the peripheral surface of the first roll, the first embossing pattern comprising protrusions and recessions;
• and
• the second embossing roll has a second embossing pattern engraved on at least a portion of the peripheral surface of the second embossing roll, the second embossing pattern comprising protrusions and recessions, and
• wherein the protrusions of the first embossing pattern of the first embossing roll become inter-engaged at a radial depth of engagement with the corresponding recessions of the second embossing pattern of the second embossing roll such that at least 99.7% of the inter-engaged protrusions and recessions are separated from each other by a sidewall clearance ranging from about 0.002″ (about 0.050 mm) to about 0.050″ (about 1.27 mm);
• b) coating the top surfaces of at least a portion of the protrusions of a third embossing roll with an active substance, the third embossing roll having a third embossing pattern engraved on at least a portion of the peripheral surface of the third embossing roll, the third embossing pattern comprising protrusions and recessions, and
• wherein the protrusions of the first embossing pattern of the first embossing roll become inter-engaged with the corresponding recessions of the third embossing pattern of the third embossing roll;
• and
• c) passing the embossed web material between a first embossing roll and the third embossing roll engaged with the first embossing roll, to transfer the active substance to the deformable web material to form the embossed web material having an active substance.